Method and apparatus for charging and discharging a rechargeable battery

ABSTRACT

A battery protection system is provided for a rechargeable battery. The system has a switch module that selectively interrupts battery current based on a control signal, a battery voltage sensor that senses battery voltage, a battery temperature sensor that generates a battery temperature signal, and a control module that generates said control signal based on said battery temperature signal and said battery voltage.

FIELD OF THE INVENTION

The present invention relates generally to battery systems, and more particularly to a battery charger for battery systems.

BACKGROUND OF THE INVENTION

Rechargeable batteries, particularly nickel-metal hydride (NiMH) batteries, are useful in many types of applications. For example, the batteries may be used as a backup power supply for stationary applications such as cellular towers. The batteries provide backup power during a main grid outage. In such an application, it is desirable that the batteries are connected to a battery charging circuit that maintains the state of charge of the batteries. Under certain circumstances, charging NiMH batteries may cause the batteries to overheat, which may damage the batteries or other components.

SUMMARY OF THE INVENTION

A battery protection system is provided for a rechargeable battery. The system has a switch module that selectively interrupts battery current based on a control signal, a battery voltage sensor that senses battery voltage, a battery temperature sensor that generates a battery temperature signal, and a control module that generates the control signal based on the battery temperature signal and the battery voltage.

A battery protection circuit is also provided. The circuit has a switch module that selectively interrupts battery current based on a control signal. A first oscillator module generates a first signal having a first period and a temperature dependent oscillator module generates a second signal having a second period. A duty cycle generator receives the first signal and the second signal, and generates the control signal. The control signal is pulse-width modulated at the first period with a duty cycle established by the second period.

A method for protecting a rechargeable battery is provided. The method includes monitoring a battery temperature and monitoring a battery voltage, and selectively interrupting current flow to the battery based on the battery temperature and the battery voltage.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a block diagram and electrical schematic of a rechargeable power supply;

FIG. 2A is a functional block diagram of the power supply of FIG. 1 being used as a primary power supply for a load;

FIG. 2B is a functional block diagram of the power supply of FIG. 1 being recharged;

FIG. 2C is a functional block diagram of the power supply of FIG. 1 being used as a backup power supply in combination with a primary power supply;

FIG. 3 is a graph of operating voltage as a function of depth of discharge (DOD) at 25° C.;

FIG. 4 is an electrical schematic of an exemplary switch module;

FIG. 5 is a flowchart illustrating steps of a method for charging rechargeable batteries;

FIG. 6 is a functional block diagram of a battery charger according to some implementations of the present invention;

FIG. 7 is an electrical schematic of one implementation of the battery charger of FIG. 6;

FIG. 7A depicts waveforms of the battery charger of FIG. 7; and

FIG. 8 is a perspective view of a rechargeable power supply.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the term module and/or device refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. For purposes of clarity, the same reference numerals will be used to identify similar elements.

Referring now to FIG. 1, a block diagram and electrical schematic of a rechargeable power supply 2 is shown. The power supply 2 has a housing 4 containing a battery 6. The battery 6 has a number of individual cells 8 a, 8 b, . . . , 8 n, collectively referred to as cells 8. In some implementations, the cells 8 may be nickel-metal hydride (NiMH) cells, although other types of batteries may be used. A positive battery terminal 10 is connected to a power supply positive terminal 12 by a positive bus 14. A switch module 16 selectively connects a negative battery terminal 18 to a negative bus 20. The negative bus 20 is connected to a power supply negative terminal 22. The positive and negative power supply terminals 12, 22 are preferably positioned along an end face of the housing 4, thereby facilitating electrical interconnection of a plurality of the rechargeable power supplies 2. An intermediate connection 24 connects the negative battery terminal 18 to the switch module 16. A switch control module 26 generates a switch control signal 28 based on battery voltage and temperature as will be described below. A resettable circuit breaker or fuse (not shown) may also be placed in series with the battery 6.

Referring now to FIG. 2A, the power supply 2 is shown connected to a load 30. The battery 6 of the power supply 2 provides current to the load 30 when the switch module 16 is closed. The switch control module 26 will open the switch module 16 via the switch control signal 28 if the battery temperature is above a predetermined threshold.

Referring now to FIG. 2B, the power supply 2 is shown connected to a charging device 32. The charging device 32 provides power to recharge the battery 6 of the power supply 2. The switch control module 26 monitors the voltage and the temperature of the battery 6, and controls charging of the battery 6 in accordance with a method described later.

Referring now to FIG. 2C, a primary supply 34 is connected across the load 30 and the power supply 2. The primary supply 34 provides power to power the load 30 and/or to charge the battery 6 in the power supply 2. If the primary supply 34 stops providing current, such as may happen during a power outage, the power supply 2 continues providing current to the load 30 until the primary supply 34 is restored. The amount of time that the power supply 2 can provide power is determined by several factors including the capacity (amp-hours) of the battery 6, the state of charge (SOC) of the battery 6 at the time the primary supply 34 failed, the temperature of the battery 6, and the current drawn by the load 30.

Referring now to FIG. 3, a family of curves 36 of a NiMH battery 6 is shown. A y-axis 38 indicates battery voltage and an x-axis 40 indicates degree of discharge (DOD) of each battery 6. The family of curves 36 provides an indication of the voltage vs DOD at 25 deg. C. It can be seen that the battery voltage increases rapidly as DOD decreases. A cutoff voltage, or V_(CUTOFF), 42 is selected to provide an indication that the battery 6 is fully charged.

Referring now to FIG. 4, an exemplary switch module 16 is shown. The switch module 16 may be implemented using any combination of electromechanical relays, transistors, electronic and integrated circuits, and/or any material having very high and very low states of resistance. The depicted switch module 16 includes NMOS transistors Q₁, Q₂, and Q₃. A source of each transistor Q₁₋₃ is connected to the negative bus 20. A drain of each transistor Q₁₋₃ is connected to the intermediate connection 24. A gate of each transistor Q₁₋₃ is connected to the switch control signal 28. The switch module 16 may also include an indicator, such as an LED 44 with a current limiting resistor 46, to indicate whether the switch module is open or closed while the battery 6 is charging.

Referring now to FIG. 5, steps of a method for generating a switch control signal 28 are shown. In the described embodiment, the switch control signal is a PWM signal having a duty cycle between 0 and 100%, however it is understood that other types of control signals and/or other duty cycles may be used to control the switch module 16.

The method begins in step 48. In step 50, control determines whether temperature T_(BATT) of the battery 6 is above a predetermined temperature threshold T_(H). If the determination made in step 46 returns a true result, then control proceeds to step 52 and opens the switch module 16 by setting the duty cycle (DC) to zero percent. In step 50, if T_(BATT) is below T_(H) then control proceeds to decision block 54 and determines whether the voltage V_(BATT) of the battery 6 is less than the predetermined battery voltage threshold V_(CUTOFF). If the determination made in step 54 returns a true result, then control proceeds to step 56. In step 56, control closes the switch module 16 by setting the duty cycle to one hundred percent. Returning to step 54, if V_(BATT) is equal to or greater than the predetermined battery voltage threshold V_(CUTOFF), then control proceeds to step 58 and establishes a first time period T₁. Control then proceeds to step 60 and generates a second time period T₂, which is temperature compensated by T_(BATT). The time period T₂ decreases as T_(BATT) increases. In step 62, control generates a switch control signal 28 having a DC that is derived from T₁ and T₂.

Referring now to FIG. 6, a functional block diagram of a switch control module 26 is shown. A temperature sensor 64 indicates the battery temperature T_(BATT). A thermostat 66 compares T_(BATT) to T_(H) and provides a switch enable signal SW_EN to a driver 68. When T_(BATT) is greater than T_(H), the thermostat 66 opens the switch module 16 by turning off the driver 68.

When T_(BATT) is less than or equal to T_(H), the driver 68 produces a PWM signal having a duty cycle that is set by a duty cycle (DC) generator 70. The duty cycle generator 70 produces a 100% duty cycle signal when a voltage sensor 72 and a comparator 74 determine that the battery voltage V_(BATT) is less than the cutoff voltage V_(CUTOFF). When the voltage sensor 72 and the comparator 74 determine that the battery voltage V_(BATT) is greater than the cutoff voltage V_(CUTOFF), the duty cycle generator 70 produces a duty cycle signal based on periods T₁ and T₂. The period T₁ is derived from an oscillator module 76 and period T₂ has a variable value generated by a temperature compensated oscillator 78. The temperature compensated oscillator 78 is synchronized with the period T₁. The period T₂ varies as a function of T_(BATT). In some implementations, the period T₂ of the temperature compensated oscillator 78 decreases as T_(BATT) increases.

Referring now to FIGS. 7 and 7A, one exemplary circuit that implements the switch control module 26 of FIG. 6 is described. The battery voltage V_(BATT) is taken directly from the positive battery terminal 10 and ground is connected to the negative battery terminal 18. A power supply voltage V_(CC) is derived by passing V_(BATT) through a low-pass RC filter (not shown).

The oscillator module 76 is implemented with an integrated circuit IC₁. The integrated circuit IC₁ is a 24-stage frequency divider, such as an MC14521B. One terminal each of a resistor R_(1,) a resistor R₂, and a capacitor C_(1,) are connected together. The other end of the resistor R₁ is connected to an IN₁ input of the integrated circuit IC₁. The other end of the resistor R₂ is connected to an OUT₂ output of the integrated circuit IC₁. An input IN₂ and an output OUT₁ of the integrated circuit IC₁ are connected to the other end of the capacitor C₁. This configuration of the resistors R₁ and R₂, the capacitor C₁, and the integrated circuit IC₁, produces a square wave at an output Q₂₂ of the integrated circuit IC₁. The square wave is shown in FIG. 7A at V_(Q22). The square wave has a fixed period T₁ that is established by the resistor R₂ and the capacitor C₁. The pulse-width of the square wave V_(Q22) is ½*T₁. The square wave is output through a capacitor C₂ to a node Nd₁. The node Nd₁ is pulled up to V_(cc) through a resistor R₄. The node Nd₁ is an input to a duty cycle generator 70 and has a waveform that is dependent on the outputs of the comparator 74, a master/slave switch 80, and the oscillator module 76. The waveform of node Nd₁ will be described after the operations of the connected circuit blocks are described.

The voltage sensor 72 includes a voltage divider formed of an upper resistor R₃ and a lower resistor R₄. One end of the upper resistor R₃ is connect to V_(BATT). One end of the lower resistor R₄ is connected to ground. The other end of the upper resistor R₃ and the other end of the lower resistor R₄ are connected together to form node Nd₂, which is the center tap of the voltage divider. The node Nd₂ provides a scaled battery voltage signal.

The comparator 74 has a NAND gate NA₁ with an open collector output. The NAND gate NA₁ is configured as an inverter. An input to the inverter is a node Nd₃ located at a connection of one end of a resistor R₅ and a cathode of a 3-terminal voltage regulator Z₁. Examples of devices that may be used to implement the voltage regulator Z₁ include a TL431/TL431A/TL431B series of programmable voltage references available from Linfinity Microelectronics, Inc. The other terminal of the resistor R₅ is connected to V_(CC). An anode of the voltage regulator Z₁ is connected to ground. A reference pin of the voltage regulator Z₁ is connected to the node Nd₂. A voltage at the node Nd₃ is low when the voltage regulator Z₁ is conducting, which occurs when V_(BATT) is greater than or equal to V_(CUTOFF). A conduction point of the voltage regulator Z₁ is established by the resistors R₃ and R₄, which should have resistances selected such that voltage at the node Nd₂ causes the voltage regulator Z₁ to conduct when V_(BATT) is greater than or equal to V_(CUTOFF). An output of the NAND gate NA₁ connects to a cathode of a diode D₁. An anode of the diode D₁ connects to the node Nd₁.

A waveform at the node Nd₁ will now be described. A common pole of the master/slave switch 80 is connected to the node Nd₁. If the switch 80 is in the master position M and closing a path to ground, then the switch 80 will hold the node Nd₁ at ground. If the switch 80 is in the slave position S and V_(BATT) is less than V_(CUTOFF), then the diode D₁ will be forward biased by the comparator 74 and the voltage of the node Nd₁ will be held low. If the switch 80 is in the slave position and V_(BATT) is greater than or equal to V_(CUTOFF), then the comparator 74 will prevent the diode D₁ from conducting. The voltage of the node Nd₁ will then pulse low with each falling edge from the output Q₂₂ of the integrated circuit IC₁. The low pulses have a period T₁ as shown in FIG. 7A at V_(Nd1).

The node Nd₁ is an input to the duty cycle generator 70. The duty cycle generator 70 is formed from a set-reset (SR) flip-flop 82 fabricated of NAND gates NA₂ and NA₃. An output of the NAND gate NA₂ is connected to an input of the NAND gate NA₃. An output of the NAND gate NA₃ is connected to an input of the NAND gate NA₂. A remaining input of the NAND gate NA₂ operates as the set input of the SR flip-flop and is connected to the node Nd₁. A remaining input of the NAND gate NA₃ operates as the reset input of the SR flip-flop and is connected to the node Nd₃. An output of the duty cycle generator 70 is taken from the output of NA₂. The output voltage of the duty cycle generator 70 is high after the node Nd₁ is pulsed low, and low after the node Nd₃ is pulsed low. The output of the duty cycle generator 70 will remain high when either the switch 80 or the comparator 74 holds the node Nd1 low.

The temperature compensated oscillator 78 is formed around an integrated circuit IC₂, which is a 24-stage frequency divider such as an MC14521B. An output of a NAND gate NA₄ provides a node Nd₄. A waveform at the node Nd₄ is a logical complement of the waveform at the node Nd₁ as is shown in FIG. 7A at V_(Nd4). A Reset input of the integrated circuit IC₂ is connected to the node Nd₄. As is shown in FIG. 7A at V_(Q20), an output Q₂₀ of the integrated circuit IC₂ is low while the Reset input of the integrated circuit IC₂ is held high by the node Nd₄.

One end each of a resistor R₆, a thermistor R_(T1), and a capacitor C₃, are connected together. A remaining end of the resistor R₆ is connected to an In₁ input of the integrated circuit IC₂. A remaining end of the capacitor C₃ is connected to an output Out₁ and to an input In₂ of the integrated circuit IC₂. A remaining end of the thermistor R_(T1) is connected to an output Out₂ of the integrated circuit IC₂. The resistance of thermistor R_(T1) decreases as its temperature increases. The thermistor R_(T1) is preferably positioned in proximity to a battery 6 (not shown) that is connected to the switch module 16. An optocoupler 84 selectively couples a resistor R₇ in parallel with the thermistor R_(T1). The optocoupler 84 has an internal LED with an anode pulled up to V_(CC) by a resistor R₈. A cathode of the LED is connected to an output of the thermostat 66.

The output Q₂₀ of integrated circuit IC₂ generates a pulse train having a period T₂ and a pulsewidth of ½*T₂ as is shown in FIG. 7A at V_(Q20). The period T₂ decreases as the temperature of R_(T1) increases. The period of T₂ also decreases when R₇ is switched in parallel with R_(T1). The output Q₂₀ of the integrated circuit IC₂ is connected to a capacitor C₄ An opposite end of the capacitor C₄ is connected to the node Nd₃, which is the reset input of the duty cycle generator 70. Each time the output Q₂₀ of the integrated circuit IC₂ transitions from high to low, a low-going pulse appears at the node Nd₃ as is shown in FIG. 7A at V_(Nd3). Each low-going pulse causes the output of the duty cycle generator 70 to go low. When the node N_(d1) is carrying the pulses initiated by the output Q₂₂ of the integrated circuit IC₁, the output signal from the duty cycle generator 70 is a PWM signal. The PWM signal has a period T₁ established by the oscillator module 76 and a duty cycle established by the temperature compensated oscillator 78. An output signal of the duty cycle generator 70 operating in such a situation appears in FIG. 7A at V_(Nd5). The output signal may be used as the control signal 28 as described later.

The output signal from the duty cycle generator 70 is input to the driver 68. The driver 68 has a transistor Q₄. A resistor R₉ is connected between a base and emitter of the transistor Q₄. A resistor R₁₀ is in series with the base of the transistor Q₄. One end of a resistor R₁₄ is connected to the collector of the transistor Q₄. The other end of the resistor R₁₄ provides the switch control signal 28 and is pulled down to ground through a resistor R₁₅. The duty cycle of the switch control signal 28 is zero percent when the thermostat 66 turns off the transistor Q₄. The duty cycle of the switch control signal is greater than zero percent when the transistor Q₄ is amplifying the signal from the node Nd₅.

The thermostat 66 has a temperature controller 86. An example of a device suitable for use as the temperature controller 86 is an Analog Devices part number TMP01FS. A resistor R₁₁ is connected between a VREF output and a SETLOW input of the temperature controller 86. A resistor R₁₂ is connected between the SETLOW input and a SETHI input of the temperature controller 86. A resistor R₁₃ is connected between the SETHI input of the temperature controller 86 and ground. The temperature controller 86 has an output UNDER that is connected to the driver 68. The output UNDER of the temperature controller 86 turns the transistor Q₄ on when the battery temperature T_(BATT) is below a predetermined threshold. The thermostat 66 is therefore preferably positioned proximate the battery 6 that is connected to the switch module 16. The junction of the resistors R₁₁ and R₁₂ provides a voltage corresponding to a predetermined low battery temperature T_(L) threshold. The junction between the resistors R₁₂ and R₁₃ provides a voltage corresponding to a predetermined high battery temperature T_(H) threshold.

The OVER and UNDER outputs of the temperature controller 86 are active low. The output UNDER is low when the battery temperature T_(BATT) is less than the predetermined high battery temperature T_(H). The output OVER is low when the battery temperature T_(BATT) is greater than the predetermined low battery temperature T_(L).

The output OVER is connected to the cathode of the LED in the optoisolator 84. The LED is turned on when the output OVER goes low, thereby selectively connecting resistor R₇ in parallel with R_(T1). The thermostat 66 thereby provides a mechanism for selecting a range of period T₂ from two period ranges. The output UNDER drives the base of Q₄ and turns Q₄ off when the battery temperature T_(BATT) is greater than the high battery temperature T_(H). In the depicted embodiment, the high battery temperature T_(H) is selected to be 50 deg C. and the low battery temperature TL is selected to be 40 deg C. Other values may be used as needed to prevent the battery 6 from overheating while it is being charged.

Referring now to FIG. 8, an exterior perspective view of a rechargeable power supply 2 is shown. The power supply 2 has a battery 6 with a number of prismatic cells 8 a-e. A housing 4 contains the battery 6, a switch module 16, and a control module 26. In one of many embodiments, the master/slave switch 80 is accessible at from an exterior of the housing 4. The power supply positive terminal 12 and the negative terminal 22 are positioned on the housing 4.

A plurality of the power supplies 2 may be coupled in series with one power supply 2 having the switch 80 set to the master position, and the remaining power supplies 2 having switches 80 set to slave. Such a series configuration of power supplies 2 allows the switch control module 26 of the power supply 2 set to master to control the charging and discharging of the batteries 6 in the remaining power supplies 2 that have switches 80 set to the slave position.

Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims. 

1. A battery protection system for a rechargeable battery, comprising: a switch module that selectively interrupts battery current based on a control signal; a battery voltage sensor that senses battery voltage; a battery temperature sensor that generates a battery temperature signal; and a control module that generates said control signal based on said battery temperature signal and said battery voltage.
 2. The battery protection system of claim 1 wherein said control signal is a pulse-width modulated (PWM) waveform having a duty cycle.
 3. The battery protection system of claim 2 wherein said duty cycle is zero percent when said battery temperature exceeds a first predetermined temperature.
 4. The battery protection system of claim 3 wherein said duty cycle is one hundred percent when said battery temperature is less than said first predetermined temperature and said battery voltage is less than a predetermined voltage.
 5. The battery protection system of claim 4 wherein said duty cycle is between zero percent and one hundred percent when said battery temperature is less than said first predetermined temperature and said battery voltage is greater than said predetermined voltage.
 6. The battery protection system of claim 2 wherein said control module further comprises: a first oscillator module that generates a first signal having a first period; a temperature dependent oscillator module that generates a second signal having a second period that varies based on said battery temperature signal; and a duty cycle generator module that generates said PWM signal from said first signal and said second signal.
 7. The battery protection system of claim 6 wherein said temperature dependent oscillator module has at least two ranges of periods, said second period being within one of said at least two ranges of periods.
 8. The battery protection system of claim 7 further comprising a temperature controller for selecting which of said at least two period ranges is used by said temperature dependent oscillator.
 9. A self-protecting rechargeable power supply comprising the battery protection system of claim 1 and further comprising: a rechargeable battery; and a housing containing said rechargeable battery, battery voltage sensor, battery temperature sensor, control module, and switch module.
 10. A battery protection circuit comprising: a switch module that selectively interrupts battery current based on a control signal; a first oscillator module that generates a first signal having a first period; a temperature dependent oscillator module that generates a second signal having a second period; and a duty cycle generator that receives said first signal and said second signal and generates said control signal, wherein said control signal is pulse-width modulated at said first period with a duty cycle established by said second period.
 11. The battery protection circuit of claim 10 wherein said temperature dependent oscillator is dependent on a battery temperature.
 12. The battery protection circuit of claim 10 wherein said duty cycle generator further includes a flip-flop having a set input, a reset input, and an output, said first signal being connected to said set input and said second signal being connected to said reset input, and wherein said output performs the pulse-width modulation of said control signal.
 13. The battery protection circuit of claim 10 further comprising a thermostat module, said thermostat module controlling said control signal in accordance with a battery temperature.
 14. The battery protection circuit of claim 10 further comprising a comparator module that enables and disables said first signal based on a battery voltage.
 15. A self-protecting rechargeable power supply comprising the battery protection system of claim 10 and further comprising: a rechargeable battery; and a housing containing said rechargeable battery, said first oscillator, said temperature dependent oscillator, said duty cycle generator, and said switch module.
 16. The self-protecting rechargeable power supply of claim 15 further comprising positive and negative electrical terminals for making electrical connections, said positive and negative electrical terminals positioned on an end face of said housing.
 17. A method for protecting a rechargeable battery, comprising: monitoring a battery temperature; monitoring a battery voltage; selectively interrupting current flow to the battery based on said battery temperature and said battery voltage.
 18. The method of claim 17 wherein said step of selectively interrupting comprises: pulse width modulating the current flow to the battery at a duty cycle based on said battery temperature and said battery voltage.
 19. The method of claim 18 further comprising: setting said duty cycle to zero percent when said battery temperature exceeds a first predetermined temperature.
 20. The method of claim 19 further comprising: setting said duty cycle to one hundred percent when said battery temperature is less than a first predetermined temperature and when said battery voltage is less than a predetermined voltage.
 21. The method of claim 20 further comprising: setting said duty cycle to between zero percent and one hundred percent when said battery temperature is less than said first predetermined temperature and said battery voltage is greater than said predetermined voltage.
 22. The method of claim 18 further comprising: generating a first signal having a first period; generating a second signal having s second period that varies based on said battery temperature; and generating said duty cycle based on said first signal and said second signal.
 23. The method of claim 18 further comprising: selecting said second period from at least two ranges of periods.
 24. The method of claim 17 further comprising: providing a housing containing the rechargeable battery. 